Lattice materials and structures and related methods thereof

ABSTRACT

A method for treating substrates or components; and substrates or components that have been treated by the associated method. The treatment may be applied to any iron or steel based alloy to create a treated layer that increases the strength of the substrate or component. The treatment may be especially useful for strengthening small structures, as with sandwich panels, small trusses, or other complex structures. The treatment may be used to improve strength, stiffness, fatigue resistance, and wear properties, among other benefits.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application claims benefit of priority under 35 U.S.C. §119(e) from U.S. Provisional Application Ser. No. 61/870,734, filed Aug. 27, 2013, entitled “Micro-lattice Materials and Structures and Related Methods thereof,” U.S. Provisional Application Ser. No. 62/003,771, filed May 28, 2014, entitled “Micro-lattice Materials and Structures and Related Methods thereof;” and U.S. Provisional Application Ser. No. 62/038,441, filed Aug. 18, 2014, entitled “Micro-lattice Materials and Structures and Related Methods thereof;” the disclosures of which are hereby incorporated by reference herein in their entirety.

The present application is related to International Patent Application Serial No. PCT/US2014/xxxxxx, Wadley, et al., entitled “Three-Dimensional Space Frames Assembled from Component Pieces and Methods for Making the Same,” (Attorney Docket No. 02107-01) filed Aug. 27, 2014; the disclosure of which is hereby incorporated by reference herein in its entirety.

TECHNICAL FIELD

The present invention relates generally to the field strengthening substrates and components. More specifically, the present invention relates to micro lattice and other structures composed of iron based alloys and the method of making the same.

OVERVIEW

An aspect of an embodiment of the present invention provides, among other things, new states of matter consisting of lattice structures whose trusses have been surface modified to create ultra high-strength surface layers. The resulting low density solid material exploits synergies between nano-scale engineered surface modified layers and microlattice topology concepts leading to materials with new combinations of strength and density. Various methods for the fabrication of the structures are also considered part of the present invention, and of course may be employed within the context of the invention. Various sizes and contours of the structures are also considered part of the present invention, and of course may be employed within the context of the invention.

An aspect of an embodiment of the present invention provides, among other things, a method for strengthening a substrate or component with a treatment. The method may comprise: treating the substrate or component to be strengthened; and wherein the treatment affects a minimum of at least about 0.5 percent of the material cross-sectional area of the substrate or the component after the treatment, resulting in strengthening of the substrate or the component.

An aspect of an embodiment of the present invention provides, among other things, a strengthened substrate or component device. The substrate or component may be in communication with a treatment; and the treatment comprising a minimum of at least about 0.5 percent of the total material cross-sectional area of the substrate or component in communication with the treatment.

An aspect of an embodiment of the present invention provides, among other things, a method for treating substrates or components; and substrates or components that have been treated by the associated method. The treatment may be applied to any iron or steel based alloy to create a treated layer that increases the strength of the substrate or component. The treatment may be especially useful for strengthening small structures, as with sandwich panels, small trusses, or other complex structures. The treatment may be used to improve strength, stiffness, fatigue resistance, and wear properties, among other benefits.

These and other objects, along with advantages and features of various aspects of embodiments of the invention disclosed herein, will be made more apparent from the description, drawings and claims that follow.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated into and form a part of the instant specification, illustrate several aspects and embodiments of the present invention and, together with the description herein, serve to explain the principles of the invention. The drawings are provided only for the purpose of illustrating select embodiments of the invention and are not to be construed as limiting the invention.

FIG. 1A provides a schematic perspective view of an aspect of an embodiment of the present invention substrate or component.

FIG. 1B provides an enlarged cross-section view of FIG. 1A.

FIG. 1C provides a schematic perspective view of an aspect of an embodiment of the present invention substrate or component.

FIG. 1D provides an enlarged cross-section view of FIG. 1C.

FIG. 2 provides a micrographic depiction of a cross-sectional view (partial view) of a nitro-carburized 304 stainless steel tube.

FIGS. 3A, 3B and 3D provide a cross-sectional view of a component or substrate with a treatment provided for strengthening the substrate or component that is generally hollow.

FIG. 3C provides a cross-sectional view of a component or substrate that is generally solid with a treatment provided for strengthening the substrate or component.

FIGS. 4A, 4B and 4D provide a cross-sectional view of a component or substrate with a treatment provided for strengthening the substrate or component that is generally hollow.

FIG. 4C provides a cross-sectional view of a component or substrate that is generally solid with a treatment provided for strengthening the substrate or component.

FIG. 5A provides an enlarged partial view of FIG. 5B of a unit cell with hollow trusses.

FIGS. 5B and 5C provide a schematic perspective view of an aspect of an embodiment of the present invention substrate or component. In particular, the substrate or component of FIGS. 5B and 5C, is a square and diamond orientation collinear lattice structure, respectively.

FIG. 6 is a graphical illustration that provides the strength of various 304 stainless steel lattices and compares the differences in lattice strength depending on whether or not the material of the lattices have been carburized as a form of treatment.

FIG. 7 is a graphical illustration that compares the compressive properties of annealed 304 stainless steel tubes to different thicknesses (t) of 304 stainless steel tubes that have been carburized as a form of treatment.

FIGS. 8A, 8B, and 8C are graphical illustrations that provide the compressive properties of various 465 stainless steel tubes (wall thickness=216 μm) that have been treated by various hardening process:

FIGS. 8D, 8E, and 8F provide photographic depictions of the buckling modes of the tubes for the respective treated tubes provided in FIGS. 8A, 8B, and 8C.

FIG. 9 is a graphical illustration that provides the predicted strength of various 304 stainless steel lattices and compares the differences in lattice strength depending on whether or not the material of the lattices have been carburized as a form of treatment. FIG. 9 also provides a graphical illustration that provides the strength of various 465 stainless steel lattices and compares the differences in lattice strength depending on whether or not the material of the lattices has been nitro-carburized as a form of treatment.

FIGS. 10A, 10B, and 10C are graphical illustrations that provide the compressive properties of various 465 Carpenter® steel unit cell hollow pyramidal lattices that have been treated by various hardening process.

FIGS. 10D, 10E, and 10F provide photographic depictions of the buckling of the pyramidal lattices for the respective treated lattices provided in FIGS. 10A, 10B, and 10C.

FIG. 11 provides a graphical illustration of the tensile properties regarding a treated 316 stainless steel foil having a 75 μm thickness.

FIG. 12 is a graphical illustration that provides the predicted strength of various 304 stainless steel lattices and compares the differences in lattice strength depending on whether or not the material of the lattices have been carburized as a form of treatment. FIG. 12 also provides is a graphical illustration that provides the strength of various 465 stainless steel lattices and compares the differences in lattice strength depending on whether or not the material of the lattices have been nitro-carburized as a form of treatment. FIG. 12 additionally provides a graphical illustration that provides the predicted strength of a 316 stainless steel pyramidal lattice.

FIGS. 13A, 14A and 15A, schematically illustrate the exploded view (or pre-assembly view) of an embodiment of the present invention substrate or component that may include a lattice of varying types that may include tetrahedral truss, pyramidal truss, and 3K Kagome truss and their corresponding in-plane struts.

FIGS. 13B, 14B and 15B schematically illustrate the assembled view of the substrate or component 21 of FIGS. 13A, 14A and 15A, respectively.

FIG. 16 provides schematic perspective views of examples of periodic cellular material topologies as an aspect of various embodiments of the present invention. FIGS. 16(A)-(C) include exemplary honeycomb structures that respectively comprise hexagonal cell, square cell, and triangular cell structures. FIGS. 16 (D)-(F) schematically illustrate exemplary corrugated structures that may include triangular corrugation, diamond or multi-layered corrugation, and flat-top or sometimes referred to as Navtruss® corrugation arrangements, respectively. FIGS. 16(G)-(I) schematically illustrate a tetrahedral structural arrangement; a pyramidal structural arrangement; a three-dimensional Kagomé structural arrangement, respectively.

FIG. 17 provide a schematic perspective view of a two layer periodic cellular material (PCM) panel that combines Square Honeycomb core and a Pyramidal Trusscore as an aspect of an embodiment of the invention.

DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENTS

FIG. 1A provides a schematic perspective view of an aspect of an embodiment of the present invention substrate or component 21. In particular, the substrate or component 21 of FIG. 1A is a hollow tetrahedral lattice unit cell with three struts 22. FIG. 1B provides an enlarged cross-section view of FIG. 1A. Turing to FIG. 1B, provided is the component or substrate 21 with a treatment provided for strengthening the substrate or component 21 (e.g., strut), wherein disposed therewith is an exterior portion 41 and interior portion 31. Still referring to FIG. 1B, also shown is a gap 55 within the material of the substrate or component 21 (e.g., strut), exterior portion 41 and interior portion 31. At a given location on the substrate or component 21, the cross-section distance 51 of the material of the substrate or component 21 (e.g., strut), exterior portion 41 and interior portion 31 may be determined. A material cross-sectional area may be determined by the area defined by the cross-section distance 51 integrated (as in transposing the dimension of the cross-section distance 51) across the material to define an area.

FIG. 1C provides a schematic perspective view of an aspect of an embodiment of the present invention substrate or component 21. In particular, the substrate or component 21 of FIG. 1C is a solid tetrahedral lattice unit cell with three struts 22. FIG. 1D provides an enlarged cross-section view of FIG. 1C. Turing to FIG. 1D, provided is the component or substrate 21 with a treatment provided for strengthening the substrate or component 21 (e.g., strut), wherein disposed therewith is an exterior portion 41. Still referring to FIG. 1D, at a given location on the substrate or component 21, the cross-section distance 51 of the material of the substrate or component 21 (e.g., strut) and exterior portion 41 may be determined. A material cross-sectional area may be determined by the area defined by the cross-section distance 51 integrated (as in transposing the dimension of the cross-section distance 51) across the material to define an area.

As generally reflected in FIG. 1, an aspect of an embodiment provides a method for strengthening the substrate or component 21 with a treatment. The method of fabrication may comprise: treating the substrate or component 21 to be strengthened; and wherein said treatment affects a minimum of at least about 0.5 percent of the material cross-sectional area of said substrate or said component after said treatment, resulting in strengthening of said substrate or said component. In an embodiment, the substrate or component 21 is in communication with a treatment; and the treatment may comprises a minimum of at least about 0.5 percent of the total material cross-sectional area of said substrate or component in communication with said treatment. In aspect of an embodiment of the present invention, the treatment may affect at least about the following percentage of the material cross-sectional area:

a) 0.5, 1.0, 1.5, 2.0, 2.5, 3.0, 3.5, 4.0, 4.5, 5.0, 5.5, 6.0, 6.5, 7.0, 7.5, 8.0, 8.5, 9.0, 9.5, 10.0, 10.5, 11.0, 11.5, 12.0, 12.5, 13.0, 13.5, 14.0, 14.5, 15.0, 15.5, 16.0, 16.5, 17.0, 17.5, 18.0, 18.5, 19.0, 19.5, 20.0, 20.5, 21.0, 21.5, 22.0, 22.5, 23.0, 23.5, 24.0, 24.5, 25.0, 25.5, 26.0, 26.5, 27.0, 27.5, 28.0, 28.5, 29.0, 29.5, 30.0, 30.5, 31.0, 31.5, 32.0, 32.5, 33.0, 33.5, 34.0, 34.5, 35.0, 35.5, 36.0, 36.5, 37.0, 37.5, 38.0, 38.5, 39.0, 39.5, 40.0, 40.5, 41.0, 41.5, 42.0, 42.5, 43.0, 43.5, 44.0, 44.5, 45.0, 45.5, 46.0, 46.5, 47.0, 47.5, 48.0, 48.5, 49.0, 49.5, 50.0, 50.5, 51.0, 51.5, 52.0, 52.5, 53.0, 53.5, 54.0, 54.5, 55.0, 55.5, 56.0, 56.5, 57.0, 57.5, 58.0, 58.5, 59.0, 59.5, 60.0, 60.5, 61.0, 61.5, 62.0, 62.5, 63.0, 63.5, 64.0, 64.5, 65.0, 65.5, 66.0, 66.5, 67.0, 67.5, 68.0, 68.5, 69.0, 69.5, 70.0, 70.5, 71.0, 71.5, 72.0, 72.5, 73.0, 73.5, 74.0, 74.5, 75.0, 75.5, 76.0, 76.5, 77.0, 77.5, 78.0, 78.5 79.0, 79.5, 80.0, 80.5, 81.0, 81.5, 82.0, 82.5, 83.0, 83.5, 84.0, 84.5, 85.0, 85.5, 86.0, 86.5, 87.0, 87.5, 88.0, 88.5, 89.0, 89.5, 90.0, 90.5, 91.0, 91.5, 92.0, 92.5, 93.0, 93.5, 94.0, 94.5, 95.0, 95.5, 96.0, 96.5, 97.0, 97.5, 98.0, 98.5, 99.0, 99.5, or 100.0;

b) 0.5, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, 90, 91, 92, 93, 94, 95, 96, 97, 98, 99, or 100;

c) 0.5-1, 2-3, 4-5, 6-7, 8-9, 10-11, 12-13, 14-15, 16-17, 18-19, 20-21, 22-23, 24-25, 26-27, 28-29, 30-31, 32-33, 34-35, 36-37, 38-39, 40-41, 42-43, 44-45, 46-47, 48-49, 50-51, 52-53, 54-55, 56-57, 58-59, 60-61, 62-63, 64-65, 66-67, 68-69, 70-71, 72-73, 74-75, 76-77, 78-79, 80-81, 82-83, 84-85, 86-87, 88-89, 90-91, 92-93, 94-95, 96-97, or 98-100;

d) 0.5-5, 6-10, 11-15, 16-20, 21-25, 26-30, 31-35, 36-40, 41-45, 46-50, 51-55, 56-60, 61-65, 66-70, 71-75, 76-80, 81-85, 86-90, or 96-100;

e) 0.5-10, 11-20; 21-30, 31-40, 41-50, 51-60, 61-70, 71-80, 81-90, 91-100;

f) 10-35; 36-60; 61-80; or 81-100;

g) 0.5-20; 21-40; 41-60; 61-80; or 81-100;

h) 10-100;

i) 5-100;

j) 0.5-100;

k) 25-100;

l) 25-75;

m) 10-25;

n) 5-25;

o) 0.5-25;

p) 50-100;

q) 75-100;

r) 10-50;

s) 5-50;

t) 0.5-50

u) 40-60;

v) 30-70;

w) 20-80;

x) 25-75; or

y) 50-75.

Where a range of values is provided, it is understood that each intervening value, to the tenth of the unit of the lower limit unless the context clearly dictates otherwise, between the upper and lower limit of that range and any other stated or intervening value in that stated range, is encompassed within the invention. The upper and lower limits of these smaller ranges may independently be included in the smaller ranges and are also encompassed within the invention, subject to any specifically excluded limit in the stated range. Where the stated range includes one or both of the limits, ranges excluding either or both of those included limits are also included in the invention.

In an aspect of an embodiment of the present invention, the strengthening of the substrate or component may include an increase in one or more of the following properties: compression strength, tensile strength, shear strength, fatigue strength, or fracture toughness.

In an aspect of an embodiment of the present invention, the treating may include one or more of the following: nitriding, carburizing, or carbonitriding, or the like; as well other available treatment methods and techniques available to one skilled in the art.

In an aspect of an embodiment of the present invention, the substrate or component may include one or more of the following materials: steel, iron, low-carbon steel, iron based alloy, stainless steel, austenitic steel, martensitic steel, austenitic stainless steel, martensitic stainless steel, or the like; as well as other materials available to one skilled in the art.

In an aspect of an embodiment of the present invention, the substrate or component may include one or more of the following structures or designs: truss, micro truss, hollow component; solid component; sub-millimeter sized component, or cellular material; as well as other structures or designs available to one skilled in the art. For instance, in an aspect of an embodiment of the present invention, the substrate or component may include one or more of the following structures or designs: planar members; sandwich members; and honeycomb structures that respectively comprise hexagonal cell, square cell, and triangular cell structures; and corrugated structures that may include triangular corrugation, diamond or multi-layered corrugation, and flat-top; or any combination thereof. Still yet, in an aspect of an embodiment of the present invention, the substrate or component may include one or more of the following structures or designs; tetrahedral structural arrangement; a pyramidal structural arrangement; a three-dimensional Kagomé structural arrangement; or any combination thereof.

FIG. 2 provides a micrographic depiction of a cross-sectional view (partial view) of a nitro-carburized 304 stainless steel tube (101 μm wall thickness) showing the case hardening layers on both the inner and outer side of the tube. Accordingly, the FIG. 2 is an example of a component or substrate 21 with a treatment provided for strengthening the substrate or component 21 (e.g., tube), wherein disposed therewith is an exterior portion 41 and interior portion 31. Still referring to FIG. 2, also shown is a gap 55 within the material of the substrate or component 21 (e.g., tube), exterior portion 41 and interior portion 31. At a given location on the substrate or component 21, the cross-section distance 51 of the material of the substrate or component 21 (e.g., tube), exterior portion 41 and interior portion 31 may be determined. A material cross-sectional area of the tube may be determined by the area defined by the cross-section distance 51 integrated (as in transposing the dimension of the cross-section distance 51) across the material to define an area.

FIG. 3A provides a cross-sectional view of a component or substrate 21 with a treatment provided for strengthening the substrate or component 21 that is generally hollow, wherein disposed therewith is an exterior portion 41 and interior portion 31. Still referring to FIG. 3A, also shown is a gap 55 within the material of the substrate or component 21, exterior portion 41 and interior portion 31. At a given location on the substrate or component 21, the cross-section distance 51 of the material of the substrate or component 21, exterior portion 41 and interior portion 31 may be determined. A material cross-sectional area may be determined by the area defined by the cross-section distance 51 integrated (as in transposing the dimension of the cross-section distance 51) across the material to define an area.

FIG. 3B provides a cross-sectional view of a component or substrate 21 that is generally hollow with a treatment provided for strengthening the substrate or component 21, wherein disposed therewith is an exterior portion 41, but without an interior treated portion. Still referring to FIG. 3B, also shown is a gap 55 within the material of the substrate or component 21 and exterior portion 41. At a given location on the substrate or component 21, the cross-section distance 51 of the material of the substrate or component 21 and exterior portion 41 may be determined. A material cross-sectional area may be determined by the area defined by the cross-section distance 51 integrated (as in transposing the dimension of the cross-section distance 51) across the material to define an area.

FIG. 3D provides a cross-sectional view of a component or substrate 21 that is generally hollow with a treatment provided for strengthening the substrate or component 21, wherein disposed therewith is an interior portion 31, but without an exterior treated portion. Still referring to FIG. 3D, also shown is a gap 55 within the material of the substrate or component 21 and interior portion 31. At a given location on the substrate or component 21, the cross-section distance 51 of the material of the substrate or component 21 and interior portion 31 may be determined. A material cross-sectional area may be determined by the area defined by the cross-section distance 51 integrated (as in transposing the dimension of the cross-section distance 51) across the material to define an area.

FIG. 3C provides a cross-sectional view of a component or substrate 21 that is generally solid with a treatment provided for strengthening the substrate or component 21, wherein disposed therewith is an exterior portion 41, and the substrate or component is illustrated without a gap as the substrate or component is generally solid. Still referring to FIG. 3C, at a given location on the substrate or component 21, the cross-section distance 51 of the material of the substrate or component 21 and exterior portion 41 may be determined. A material cross-sectional area may be determined by the area defined by the cross-section distance 51 integrated (as in transposing the dimension of the cross-section distance 51) across the material to define an area.

It should be appreciated that the component or substrate of FIGS. 3A-3D, may be solid or hollow (or some combination thereof) having variety of structures and should not be limited by the specific shapes or contours as illustrated. For example, but not limited thereto, such structures may include the following: strut, ligament, tube, bar, conduit, channel, trough, hose, cable, stem, rod, shaft, pin, panels, tunnel, passage, grove, bore, trough, duct, port, or other structures as desired or required. Further, it should be appreciated that the component or substrate can take on all shapes along the entire continual geometric spectrum of manipulation of x, y and z planes to provide and meet the structural and operational requirements and demands. Similarly, it should be appreciated that the component or substrate may take on any size as desired, required, or needed.

FIG. 4A provides a cross-sectional view of a component or substrate 21 with a treatment provided for strengthening the substrate or component 21 that is generally hollow, wherein disposed therewith is an exterior portion 41 and interior portion 31. Still referring to FIG. 4A, also shown is a gap 55 within the material of the substrate or component 21, exterior portion 41 and interior portion 31. At a given location on the substrate or component 21, the cross-section distance 51 of the material of the substrate or component 21, exterior portion 41 and interior portion 31 may be determined. A material cross-sectional area may be determined by the area defined by the cross-section distance 51 integrated (as in transposing the dimension of the cross-section distance 51) across the material to define an area.

FIG. 4B provides a cross-sectional view of a component or substrate 21 that is generally hollow with a treatment provided for strengthening the substrate or component 21, wherein disposed therewith is an exterior portion 41, but without an interior treated portion. Still referring to FIG. 4B, also shown is a gap 55 within the material of the substrate or component 21 and exterior portion 41. At a given location on the substrate or component 21, the cross-section distance 51 of the material of the substrate or component 21 and exterior portion 41 may be determined. A material cross-sectional area may be determined by the area defined by the cross-section distance 51 integrated (as in transposing the dimension of the cross-section distance 51) across the material to define an area.

FIG. 4D provides a cross-sectional view of a component or substrate 21 that is generally hollow with a treatment provided for strengthening the substrate or component 21, wherein disposed therewith is an interior portion 31, but without an exterior treated portion. Still referring to FIG. 3D, also shown is a gap 55 within the material of the substrate or component 21 and interior portion 31. At a given location on the substrate or component 21, the cross-section distance 51 of the material of the substrate or component 21 and interior portion 31 may be determined. A material cross-sectional area may be determined by the area defined by the cross-section distance 51 integrated (as in transposing the dimension of the cross-section distance 51) across the material to define an area.

FIG. 4C provides a cross-sectional view of a component or substrate 21 that is generally solid with a treatment provided for strengthening the substrate or component 21, wherein disposed therewith is an exterior portion 41, and the substrate or component is illustrated without a gap as the substrate or component is generally solid. Still referring to FIG. 4C, at a given location on the substrate or component 21, the cross-section distance 51 of the material of the substrate or component 21 and exterior portion 41 may be determined. A material cross-sectional area may be determined by the area defined by the cross-section distance 51 integrated (as in transposing the dimension of the cross-section distance 51) across the material to define an area.

It should be appreciated that the component or substrate of FIGS. 4A-4D, may be solid or hollow (or some combination thereof) having variety of structures and should not be limited by the specific contours as illustrated. For example, but not limited thereto, such structures may include the following: strut, ligament, tube, bar, conduit, channel, trough, hose, cable, stem, rod, shaft, pin, panels, tunnel, passage, grove, bore, trough, duct, port, or other structures as desired or required. Further, it should be appreciated that the component or substrate can take on all shapes along the entire continual geometric spectrum of manipulation of x, y and z planes to provide and meet the structural and operational requirements and demands. Similarly, it should be appreciated that the component or substrate may take on any size as desired, required, or needed.

FIGS. 5B and 5C provide a schematic perspective view of an aspect of an embodiment of the present invention substrate or component. In particular, the substrate or component 21 of FIGS. 5B and 5C is a square and diamond orientation collinear lattice structure, respectively. FIG. 5A provides an enlarged partial view of FIG. 5B of a unit cell with hollow struts. The substrate or component 21 (and related elements) as disclosed in FIG. 5 and throughout this disclosure is treated according to the techniques, methods, materials, and compositions disclosed herein.

Similarly, a substrate or component 21, 100 (e.g., FIG. 16), 200 (e.g., FIG. 17) and related elements may be fabricated with any of the techniques, methods, materials, and compositions disclosed in International Patent Application Serial No. PCT/US2014/xxxxxx, Wadley, et al., entitled “Three-Dimensional Space Frames Assembled from Component Pieces and Methods for Making the Same,” (Attorney Docket No. 02107-01) filed Aug. 27, 2014.

Further yet, a substrate or component 21, 100 (e.g., FIG. 16), 200 (e.g., FIG. 17) may include any of the structures and related elements disclosed in International Patent Application Serial No. PCT/US2014/xxxxxx, Wadley, et al., entitled “Three-Dimensional Space Frames Assembled from Component Pieces and Methods for Making the Same,” (Attorney Docket No. 02107-01) filed Aug. 27, 2014.

It should be appreciated that an aspect of an embodiment of the present invention substrate or component that may include a lattice of varying types. For example, a lattice truss structures may include tetrahedral, pyramidal and 3K Kagome trusses and in-plane struts to support in-plane stretching forces. The lattice may be provided with a panel or flat lattice on any one or more sides to provide a sandwich type panel (e.g., top, bottom, front, back, sides, intermediate, etc.).

FIG. 6 is a graphical illustration that provides the strength of various 304 stainless steel lattices and compares the differences in lattice strength depending on whether or not the material of the lattices have been carburized as a form of treatment. Referring to the graph, the compressive stress demonstrated by square lattice with respect to relative density is increased for the carburized squared lattice compared to the annealed square lattice. Similarly, the compressive stress demonstrated by diamond lattice with respect to relative density is increased for the carburized diamond lattice compared to the annealed diamond lattice.

FIG. 7 is a graphical illustration that compares the compressive properties of annealed 304 stainless steel tubes to different thickness (t) of 304 stainless steel tubes that have been carburized as a form of treatment, where the thickness (t) is represented in millimeters (mm) at 0.51, 0.102, 0.127, and 0.203. It may be noted that the carburized tubes generally show a higher strength, and the higher the proportion of carburization the larger the improvement in strength.

FIGS. 8A, 8B, and 8C are graphical illustrations that provide the compressive properties of various 465 Carpenter® stainless steel tubes (wall thickness=216 μm) that have been treated by various hardening processes: a) regular Carpenter®, b) age hardened, and c) carbo-nitrided, respectively. The graphs compare the differences in tube strength (axial compression stress strain responses) depending on whether or not the material of the tubes have been carburized as a form of treatment.

FIGS. 8D, 8E, and 8E provide photographic depictions of the buckling modes of the tubes for the respective treated tubes provided in FIGS. 8A, 8B, and 8C.

FIG. 9 is a graphical illustration that provides the predicted strength of various 304 stainless steel lattices and compares the differences in lattice strength depending on whether or not the material of the lattices have been carburized as a form of treatment. Referring to the graph, the compressive stress demonstrated by square lattice with respect to relative density is increased for the carburized squared lattice compared to the annealed square lattice. Similarly, the compressive stress demonstrated by diamond lattice with respect to relative density is increased for the carburized diamond lattice compared to the annealed diamond lattice.

Additionally, still referring to the graph of FIG. 9, the compressive stress demonstrated by square lattice with respect to relative density is increased for the nitro-carburized squared lattice compared to the age hardened square lattice.

FIGS. 10A, 10B, and 10C are graphical illustrations that provide the compressive properties of various 465 Carpenter® steel unit cell hollow pyramidal lattices that have been treated by various hardening process: a) regular Carpenter®, b) age hardened, and c) nitro-carburized, respectively. The graphs compare the differences in lattice strength depending on whether or not the material of the lattices have been nitro-carburized as a form of treatment.

FIGS. 10D, 10E, and 10F provide photographic depictions of the buckling of the pyramidal lattices for the respective treated lattices provided in FIGS. 10A, 10B, and 10C.

FIG. 11 provides a graphical illustration of the tensile properties regarding a treated 316 stainless steel foil having a 75 μm thickness. The foil was treated to have a 50 μm carburized case. The graph compares the treated foil to the tensile properties of annealed 316 stainless steel.

FIG. 12 is a graphical illustration that provides the predicted strength of various 304 stainless steel lattices and compares the differences in lattice strength depending on whether or not the material of the lattices have been carburized as a form of treatment. Referring to the graph, the compressive stress demonstrated by square lattice with respect to relative density is increased for the carburized square lattice compared to the annealed square lattice. Similarly, the compressive stress demonstrated by diamond lattice with respect to relative density is increased for the carburized diamond lattice compared to the annealed diamond lattice.

Additionally, still referring to FIG. 12, FIG. 12 provides is a graphical illustration that provides the strength of various 465 stainless steel lattices and compares the differences in lattice strength depending on whether or not the material of the lattices have been nitro-carburized as a form of treatment. Referring to the graph, the compressive stress demonstrated by square lattice with respect to relative density is increased for the nitro-carburized square lattice compared to the age hardened square lattice.

Further yet, FIG. 12 provides a graphical illustration that provides the predicted strength of a 316 stainless steel pyramidal lattice compared to the age-hardened, annealed, carburized, and nitro-carburized square or diamond lattices.

FIGS. 13A, 14A and 15A, schematically illustrate, respectively, the exploded view (or pre-assembly view) of an embodiment of the present invention substrate or component 21 that may include a lattice of varying types. For example, a lattice truss structures may include respective tetrahedral truss 61, pyramidal truss 63, and 3K Kagome truss 65, and their corresponding in-plane struts, 67, 68, and 69. The in-plane struts may be provided for various reasons, including to support in-plane stretching forces, as well as other structural and operative objectives.

FIGS. 13B, 14B and 15B, schematically illustrate, respectively, the assembled view of an embodiment of the present invention substrate or component 21 that include the various lattice types, such as tetrahedral truss 61, pyramidal truss 63, and 3K Kagome truss 65, along with their respective in-plane struts, 67, 68, and 69. Although not shown in FIGS. 13-15, the lattice may be provided with a panel or flat lattice on any one or more sides (top, bottom, sides, front, back, etc.) to provide a sandwich type panel. The substrate or component 21 (and related elements) is treated according to the techniques, methods, materials, and compositions disclosed herein.

FIG. 16 provides schematic illustrations of the substrate or component 100 including examples of periodic cellular material topologies, such as honeycombs and corrugations that may be used for cores of sandwich panels having a first panel 71, second panel 72, and/or third (intermediate) panel 73, as well as cellular topologies that include lattice materials made from trusses such as tetrahedral, pyramidal, and 3-D Kagome. The substrate or component 100 (and related elements) is treated according to the techniques, methods, materials, and compositions disclosed herein. FIG. 16 schematically illustrates structural arrangements that may be employed in the context as an aspect of the invention, such as honeycomb structures and corrugated (prismatic) structures. FIGS. 16(A)-(C) include exemplary honeycomb structures that respectively comprise hexagonal cell, square cell, and triangular cell structures.

FIGS. 16 (D)-(F) schematically illustrate exemplary corrugated structures that may include triangular corrugation, diamond or multi-layered corrugation, and flat-top or sometimes referred to as Navtruss® corrugation arrangements, respectively.

FIGS. 16(G)-(I) schematically illustrate a tetrahedral structural arrangement; a pyramidal structural arrangement; a three-dimensional Kagomé structural arrangement, respectively. Other honeycomb or corrugated structural arrangements may, of course, be employed. It should be appreciated that any of the panels of FIG. 16 may be replaced with a flat lattice or in-plane struts, or other structures as desired or required. One example is shown in FIG. 17. The substrate or component 200 includes as sandwich type structure that comprises a first layer 210, a second layer 220 with an intermediate member 250 there between to form a core 240. On opposite sides of the sandwich structure 200 is a front panel 202 and a back panel 222. This particular, non-limiting example provides a periodic cellular material (PCM) panel 200 that combines a square honeycomb in the second layer 220 and pyramidal truss core in the first layer 210 using a thin intermediate face sheet as the intermediate layer 250. It should be appreciated that any of the panels of FIG. 17 may be replaced with a flat lattice or in-plane struts, or other structures as desired or required. The substrate or component 200 (and related elements) is treated according to the techniques, methods, materials, and compositions disclosed herein.

It should be appreciated that numerous depositing methods upon or within the substrate or component may be employed. For example, vapor deposition techniques that use high pressures for non-line of sight deposition can be used to coat lattices. For example, multisource electron beam directed vapor processes enable the deposition of complex chemistry alloys such as stainless steels. Low porosity can be achieved in these coatings using plasma activation. It should be appreciated that various available deposition methods may be utilized as desired, required or needed.

An aspect of an embodiment of the present invention may include for example, a stainless steel hollow (tubular) lattice made by directed vapor deposition of a stainless steel onto a PMMA polymer (or other polymer or materials) lattice that is then removed by heating. Hollow tubular lattices can be made from almost any metal or alloy by this method.

In an aspect of an embodiment, for example, lattices are made from thin walled tubes of strong alloys with 10 μm thick (e.g., superlattice) multilayers deposited on the interior and exterior surfaces of tube walls provides a means for making high strength lattice structures. It should be appreciated that the thickness of the tubes (or other substrates or components) may be greater or larger than 10 μm thickness as desired, required or needed. It should be appreciated that the thickness of the tubes (or other substrates or components) may be less than or smaller than 10 μm thickness as desired, required or needed.

For example, in an aspect of an embodiment, steel tubular lattices can be case hardened creating very high strength 10-20 μm thick layers on the interior and exterior surfaces. For some stainless steels that are easily formed into tubes the carburized or carbo-nitrided layers can have a hardness of 10 GPa. It should be appreciated that the case hardening layers may be greater or less than the range of 10 μm-20 μm thickness as desired, required or needed.

In an aspect of an embodiment of the present invention, carburization of stainless steels is conducted at temperatures of 400-450° C.; sufficient for high inward diffusion of carbon (or nitrogen) yet low enough to avoid the precipitation of carbides. It should be appreciated that the temperatures may be greater than or less than the 400-450° C. range as desired, required or needed.

In an aspect of an embodiment of the present invention, examples may include square and diamond topology stainless steel lattice made from 304 stainless steel tubes by brazing (or other joining techniques).

In an aspect of an embodiment of the present invention, a continuous roll-roll process may be utilized for making a single layer of a pyramidal lattice (or other lattice, sheet or foil types) from a polymer sheet (or other sheet materials). The same process can also be used to make a lattice from moderately ductile metallic alloys, for example. It should be appreciated that various forming or shaping techniques may be utilized (such as rolling, stamping, bending, cutting, etc.). as desired, required or needed.

In an aspect of an embodiment of the present invention, the process may include the perforation of a stainless steel sheet with indexing patterns at the sides of the strip.

In an aspect of an embodiment of the present invention, the process may include a twin roller for corrugating the perforated metal or polymer sheets (or sheets of other materials) to create a pyramidal lattice (or lattice of other types). It should be appreciated that other fabrication techniques may be utilized (such as rolling, stamping, bending, cutting, etc.). as desired, required or needed.

In an aspect of an embodiment of the present invention, a 38 mm thick pyramidal lattice (or other lattice type), for example, made by corrugated rolling of perforated stainless steel sheet may be treated. It should be appreciated that the thickness of the pyramidal lattice may be greater or larger than the range of 38 mm thickness as desired, required or needed. In an aspect of an embodiment of the present invention, the process may include the assembly of micro-lattices from perforated metal sheets and pyramidal lattice layers (or other lattice types). Polymers (or other materials) are adhesively bonded by metals can be brazed or spot welded (as well as other techniques of joining).

It should be appreciated that the lattices may be structures whose cells are mm to sub-mm cross-section (e.g., width, length, height, or depth of a cell) in range; cm to sub-cm cross-section (e.g., width, length, height, or depth of a cell) in range, meter to sub-meter cross-section (e.g., width, length, height, or depth of a cell) in range, or any range larger or smaller as desired, required or needed.

It should be appreciated that an aspect of an embodiment of the present invention treatment method could be applied to virtually any substrate or component that is made from a material conducive to the disclosed treatment method. That is, for example, any substrate or component composed of iron, steel, or any iron-based alloy or steel-based alloy. Accordingly, the substrate or component may be any variety of objects as desired, required or needed.

Moreover, without intent to limit the applications of the invention in any regard, some example applications demonstrating the use of the substrate or component may include any combination of one or more of the following:

a) an architectural structure (for example: pillars, walls, shielding, foundations or floors for tall buildings or pillars, wall shielding floors, for regular buildings and houses),

b) a civil engineering field structure (for example: road facilities such as noise resistant walls and crash barriers, road paving materials, permanent and portable aircraft landing runways, pipes, segment materials for tunnels, segment materials for underwater tunnels, tube structural materials, main beams of bridges, bridge floors, girders, cross beams of bridges, girder walls, piers, bridge substructures, towers, dikes and dams, guide ways, railroads, ocean structures such as breakwaters and wharf protection for harbor facilities, floating piers/oil excavation or production platforms, airport structures such as runways), military security/protection/defense structures,

c) a machine structure (for example: frame structures for carrying system, carrying pallets, frame structure for robots, etc.),

d) an automobile structure (for example: body, frame, doors, chassis, roof and floor, side beams, bumpers, etc.),

e) a ship structure (for example: main frame of the ship, body, deck, partition wall, wall, etc.),

f) a freight car structure (for example: body, frame, floor, wall, etc.),

g) an aircraft structure (for example: wing, main frame, body, floor, etc.),

h) a spacecraft structure (for example: body, frame, floor, wall, etc.),

i) a space station structure (for example: the main body, floor, wall, etc.),

j) a submarine, ship or water craft structure (for example: body, frame, etc.), and

k) a blast, ballistic, projectile, shock or impact resistant structure (or any combination thereof).

EXAMPLES

Practice of an aspect of an embodiment (or embodiments) of the invention will be still more fully understood from the following examples and experimental results, which are presented herein for illustration only and should not be construed as limiting the invention in any way.

Example and Experimental Results Set No. 1

Collinear lattice structures with 304 stainless steel hollow trusses were fabricated with an alternating collinear lay-up process and bonded by a vacuum brazing method. Square and diamond topologies with relative densities between 0.03 and 0.11 were manufactured in this way. A low temperature nitro-carburization treatment was then performed on the collinear lattice cores at a temperature of 440° C. for 20 hours. The treatment created a thin but extremely hard surface layer on the interior and external surfaces of the hollow trusses which significantly increased the strength and buckling resistance of the individual trusses. Compressive strength enhancements compared with the untreated counterparts in the annealed (as brazed) condition varied from 1.2 for thick walled tubes to 3 for wall thicknesses that approached twice the hardened layer depth. The moduli and strengths of the lattices were found to increase with lattice relative density, and are well predicted by micromechanical model predictions. The lowest relative density (thinnest wall) nitro-carburized hollow truss collinear lattice structures exhibited a higher specific compressive strength than any other cellular metal topology reported to date. The nitro-carburized stainless steel collinear lattices appear to be promising candidates for lightweight sandwich panel cores intended for elevated temperature and/or multifunctional applications.

Additional Examples Example 1

A method for strengthening a substrate or component with a treatment. The method may comprise: treating the substrate or component to be strengthened; and wherein said treatment affects a minimum of at least about 0.5 percent of the material cross-sectional area of said substrate or said component after said treatment, resulting in strengthening of said substrate or said component.

Example 2

The method of example 1, wherein said treatment affects at least about the following percentage of the material cross-sectional area:

0.5, 1.0, 1.5, 2.0, 2.5, 3.0, 3.5, 4.0, 4.5, 5.0, 5.5, 6.0, 6.5, 7.0, 7.5, 8.0, 8.5, 9.0, 9.5, 10.0, 10.5, 11.0, 11.5, 12.0, 12.5, 13.0, 13.5, 14.0, 14.5, 15.0, 15.5, 16.0, 16.5, 17.0, 17.5, 18.0, 18.5, 19.0, 19.5, 20.0, 20.5, 21.0, 21.5, 22.0, 22.5, 23.0, 23.5, 24.0, 24.5, 25.0, 25.5, 26.0, 26.5, 27.0, 27.5, 28.0, 28.5, 29.0, 29.5, 30.0, 30.5, 31.0, 31.5, 32.0, 32.5, 33.0, 33.5, 34.0, 34.5, 35.0, 35.5, 36.0, 36.5, 37.0, 37.5, 38.0, 38.5, 39.0, 39.5, 40.0, 40.5, 41.0, 41.5, 42.0, 42.5, 43.0, 43.5, 44.0, 44.5, 45.0, 45.5, 46.0, 46.5, 47.0, 47.5, 48.0, 48.5, 49.0, 49.5, 50.0, 50.5, 51.0, 51.5, 52.0, 52.5, 53.0, 53.5, 54.0, 54.5, 55.0, 55.5, 56.0, 56.5, 57.0, 57.5, 58.0, 58.5, 59.0, 59.5, 60.0, 60.5, 61.0, 61.5, 62.0, 62.5, 63.0, 63.5, 64.0, 64.5, 65.0, 65.5, 66.0, 66.5, 67.0, 67.5, 68.0, 68.5, 69.0, 69.5, 70.0, 70.5, 71.0, 71.5, 72.0, 72.5, 73.0, 73.5, 74.0, 74.5, 75.0, 75.5, 76.0, 76.5, 77.0, 77.5, 78.0, 78.5 79.0, 79.5, 80.0, 80.5, 81.0, 81.5, 82.0, 82.5, 83.0, 83.5, 84.0, 84.5, 85.0, 85.5, 86.0, 86.5, 87.0, 87.5, 88.0, 88.5, 89.0, 89.5, 90.0, 90.5, 91.0, 91.5, 92.0, 92.5, 93.0, 93.5, 94.0, 94.5, 95.0, 95.5, 96.0, 96.5, 97.0, 97.5, 98.0, 98.5, 99.0, 99.5, or 100.0;

0.5, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, 90, 91, 92, 93, 94, 95, 96, 97, 98, 99, or 100;

0.5-1, 2-3, 4-5, 6-7, 8-9, 10-11, 12-13, 14-15, 16-17, 18-19, 20-21, 22-23, 24-25, 26-27, 28-29, 30-31, 32-33, 34-35, 36-37, 38-39, 40-41, 42-43, 44-45, 46-47, 48-49, 50-51, 52-53, 54-55, 56-57, 58-59, 60-61, 62-63, 64-65, 66-67, 68-69, 70-71, 72-73, 74-75, 76-77, 78-79, 80-81, 82-83, 84-85, 86-87, 88-89, 90-91, 92-93, 94-95, 96-97, or 98-100;

0.5-5, 6-10, 11-15, 16-20, 21-25, 26-30, 31-35, 36-40, 41-45, 46-50, 51-55, 56-60, 61-65, 66-70, 71-75, 76-80, 81-85, 86-90, or 96-100;

0.5-10, 11-20; 21-30, 31-40, 41-50, 51-60, 61-70, 71-80, 81-90, 91-100;

10-35; 36-60; 61-80; or 81-100;

0.5-20; 21-40; 41-60; 61-80; or 81-100;

10-100;

5-100;

0.5-100;

25-100;

25-75;

10-25;

5-25;

0.5-25;

50-100;

75-100;

10-50;

5-50;

0.5-50

40-60;

30-70;

20-80;

25-75 or

50-75.

Example 3

The method of example 1 (as well as subject matter of example 2), wherein said strengthening comprises an increase in compression strength.

Example 4

The method of example 1 (as well as subject matter of one or more of any combination of examples 2-3), wherein said strengthening comprises an increase in tensile strength.

Example 5

The method of example 1 (as well as subject matter of one or more of any combination of examples 2-4), wherein said strengthening comprises an increase in shear strength.

Example 6

The method of example 1 (as well as subject matter of one or more of any combination of examples 2-5), wherein said strengthening comprises an increase in fatigue strength.

Example 7

The method of example 1 (as well as subject matter of one or more of any combination of examples 2-6), wherein said strengthening comprises an increase in fracture toughness.

Example 8

The method of example 1 (as well as subject matter of one or more of any combination of examples 2-7), wherein said treating comprises nitriding.

Example 9

The method of example 1 (as well as subject matter of one or more of any combination of examples 2-8), wherein said treating comprises carburizing.

Example 10

The method of example 1 (as well as subject matter of one or more of any combination of examples 2-9), wherein said treating comprises carbonitriding.

Example 11

The method of example 1 (as well as subject matter of one or more of any combination of examples 2-10), wherein said substrate or component comprises steel.

Example 12

The method of example 1 (as well as subject matter of one or more of any combination of examples 2-11), wherein said substrate or component comprises iron.

Example 13

The method of example 1 (as well as subject matter of one or more of any combination of examples 2-12), wherein said substrate or component comprises low-carbon steel.

Example 14

The method of example 1 (as well as subject matter of one or more of any combination of examples 2-13), wherein said substrate or component comprises an iron based alloy.

Example 15

The method of example 1 (as well as subject matter of one or more of any combination of examples 2-14), wherein said substrate or component comprises stainless steel.

Example 16

The method of example 1 (as well as subject matter of one or more of any combination of examples 2-15), wherein said substrate or component comprises austenitic steel.

Example 17

The method of example 1 (as well as subject matter of one or more of any combination of examples 2-16), wherein said substrate or component comprises martensitic steel.

Example 18

The method of example 1 (as well as subject matter of one or more of any combination of examples 2-17), wherein said substrate or component comprises austenitic stainless steel.

Example 19

The method of example 1 (as well as subject matter of one or more of any combination of examples 2-18), wherein said substrate or component comprises martensitic stainless steel.

Example 20

The method of example 1 (as well as subject matter of one or more of any combination of examples 2-19), wherein said substrate or component is a micro truss.

Example 21

The method of example 1 (as well as subject matter of one or more of any combination of examples 2-20), wherein said substrate or component is a hollow component.

Example 22

The method of example 1 (as well as subject matter of one or more of any combination of examples 2-21), wherein said substrate or component is a solid component.

Example 23

The method of example 1 (as well as subject matter of one or more of any combination of examples 2-22), wherein said substrate or component is a sub-millimeter sized component.

Example 24

The method of example 1 (as well as subject matter of one or more of any combination of examples 2-23), wherein said substrate or component is a cellular material.

Example 25

The method of example 1 (as well as subject matter of one or more of any combination of examples 2-24), wherein said treatment is disposed on an exterior portion of said substrate or component.

Example 26

The method of example 1 (as well as subject matter of one or more of any combination of examples 2-25), wherein said treatment is disposed on an interior portion of said substrate or component.

Example 27

The method of example 1 (as well as subject matter of one or more of any combination of examples 2-26), wherein said treatment is disposed on an exterior portion and an interior portion of said substrate or component.

Example 28

A strengthened substrate or component. The substrate or component may be in communication with a treatment; and said treatment comprising a minimum of at least about 0.5 percent of the total material cross-sectional area of said substrate or component in communication with said treatment.

Example 29

The substrate or component of example 28, wherein said treatment affects at least about the following percentage of the material cross-sectional area:

0.5, 1.0, 1.5, 2.0, 2.5, 3.0, 3.5, 4.0, 4.5, 5.0, 5.5, 6.0, 6.5, 7.0, 7.5, 8.0, 8.5, 9.0, 9.5, 10.0, 10.5, 11.0, 11.5, 12.0, 12.5, 13.0, 13.5, 14.0, 14.5, 15.0, 15.5, 16.0, 16.5, 17.0, 17.5, 18.0, 18.5, 19.0, 19.5, 20.0, 20.5, 21.0, 21.5, 22.0, 22.5, 23.0, 23.5, 24.0, 24.5, 25.0, 25.5, 26.0, 26.5, 27.0, 27.5, 28.0, 28.5, 29.0, 29.5, 30.0, 30.5, 31.0, 31.5, 32.0, 32.5, 33.0, 33.5, 34.0, 34.5, 35.0, 35.5, 36.0, 36.5, 37.0, 37.5, 38.0, 38.5, 39.0, 39.5, 40.0, 40.5, 41.0, 41.5, 42.0, 42.5, 43.0, 43.5, 44.0, 44.5, 45.0, 45.5, 46.0, 46.5, 47.0, 47.5, 48.0, 48.5, 49.0, 49.5, 50.0, 50.5, 51.0, 51.5, 52.0, 52.5, 53.0, 53.5, 54.0, 54.5, 55.0, 55.5, 56.0, 56.5, 57.0, 57.5, 58.0, 58.5, 59.0, 59.5, 60.0, 60.5, 61.0, 61.5, 62.0, 62.5, 63.0, 63.5, 64.0, 64.5, 65.0, 65.5, 66.0, 66.5, 67.0, 67.5, 68.0, 68.5, 69.0, 69.5, 70.0, 70.5, 71.0, 71.5, 72.0, 72.5, 73.0, 73.5, 74.0, 74.5, 75.0, 75.5, 76.0, 76.5, 77.0, 77.5, 78.0, 78.5 79.0, 79.5, 80.0, 80.5, 81.0, 81.5, 82.0, 82.5, 83.0, 83.5, 84.0, 84.5, 85.0, 85.5, 86.0, 86.5, 87.0, 87.5, 88.0, 88.5, 89.0, 89.5, 90.0, 90.5, 91.0, 91.5, 92.0, 92.5, 93.0, 93.5, 94.0, 94.5, 95.0, 95.5, 96.0, 96.5, 97.0, 97.5, 98.0, 98.5, 99.0, 99.5, or 100.0;

0.5, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, 90, 91, 92, 93, 94, 95, 96, 97, 98, 99, or 100;

0.5-1, 2-3, 4-5, 6-7, 8-9, 10-11, 12-13, 14-15, 16-17, 18-19, 20-21, 22-23, 24-25, 26-27, 28-29, 30-31, 32-33, 34-35, 36-37, 38-39, 40-41, 42-43, 44-45, 46-47, 48-49, 50-51, 52-53, 54-55, 56-57, 58-59, 60-61, 62-63, 64-65, 66-67, 68-69, 70-71, 72-73, 74-75, 76-77, 78-79, 80-81, 82-83, 84-85, 86-87, 88-89, 90-91, 92-93, 94-95, 96-97, or 98-100;

0.5-5, 6-10, 11-15, 16-20, 21-25, 26-30, 31-35, 36-40, 41-45, 46-50, 51-55, 56-60, 61-65, 66-70, 71-75, 76-80, 81-85, 86-90, or 96-100;

0.5-10, 11-20; 21-30, 31-40, 41-50, 51-60, 61-70, 71-80, 81-90, 91-100;

10-35; 36-60; 61-80; or 81-100;

0.5-20; 21-40; 41-60; 61-80; or 81-100;

10-100;

5-100;

0.5-100;

25-100;

25-75;

10-25;

5-25;

0.5-25;

50-100;

75-100;

10-50;

5-50;

0.5-50

40-60;

30-70;

20-80;

25-75; or

50-75.

Example 30

The substrate or component of example 28 (as well as subject matter of one or more of any combination of example 29), wherein said strengthening comprises an increase in compression strength.

Example 31

The substrate or component of example 28 (as well as subject matter of one or more of any combination of examples 29-30), wherein said strengthening comprises an increase in tensile strength.

Example 32

The substrate or component of example 28 (as well as subject matter of one or more of any combination of examples 29-31), wherein said strengthening comprises an increase in shear strength.

Example 33

The substrate or component of example 28 (as well as subject matter of one or more of any combination of examples 29-32), wherein said strengthening comprises an increase in fatigue strength.

Example 34

The substrate or component of example 28 (as well as subject matter of one or more of any combination of examples 29-33), wherein said strengthening comprises an increase in fracture toughness.

Example 35

The substrate or component of example 28 (as well as subject matter of one or more of any combination of examples 29-34), wherein said treated percentage has been nitrided.

Example 36

The substrate or component or component of example 28 (as well as subject matter of one or more of any combination of examples 29-35), wherein said treated percentage has been carburized.

Example 37

The substrate or component of example 28 (as well as subject matter of one or more of any combination of examples 29-36), wherein said treated percentage has been carbonitrided.

Example 38

The substrate or component of example 28 (as well as subject matter of one or more of any combination of examples 29-37), wherein said substrate or component comprises steel.

Example 39

The substrate or component of example 28 (as well as subject matter of one or more of any combination of examples 29-38), wherein said substrate or component comprises iron.

Example 40

The substrate or component of example 28 (as well as subject matter of one or more of any combination of examples 29-39), wherein said substrate or component comprises low-carbon steel.

Example 41

The substrate or component of example 28 (as well as subject matter of one or more of any combination of examples 29-40), wherein said substrate or component comprises an iron based alloy.

Example 42

The substrate or component of example 28 (as well as subject matter of one or more of any combination of examples 29-41), wherein said substrate or component comprises stainless steel.

Example 43

The substrate or component of example 28 (as well as subject matter of one or more of any combination of examples 29-42), wherein said substrate or component comprises austenitic steel.

Example 44

The substrate or component of example 28 (as well as subject matter of one or more of any combination of examples 29-43), wherein said substrate or component comprises martensitic steel.

Example 45

The substrate or component of example 28 (as well as subject matter of one or more of any combination of examples 29-44), wherein said substrate or component comprises austenitic stainless steel.

Example 46

The substrate or component of example 28 (as well as subject matter of one or more of any combination of examples 29-45), wherein said substrate or component comprises martensitic stainless steel.

Example 47

The substrate or component of example 28 (as well as subject matter of one or more of any combination of examples 29-46), wherein said substrate or component is a micro truss.

Example 48

The substrate or component of example 28 (as well as subject matter of one or more of any combination of examples 29-47), wherein said substrate or component is a hollow component.

Example 49

The substrate or component of example 28 (as well as subject matter of one or more of any combination of examples 29-48), wherein said substrate or component is a solid component.

Example 50

The substrate or component of example 28 (as well as subject matter of one or more of any combination of examples 29-49), wherein said substrate or component is a sub-millimeter sized component.

Example 51

The substrate or component of example 28 (as well as subject matter of one or more of any combination of examples 29-50), wherein said substrate or component is a cellular material.

Example 52

The substrate or component of example 28 (as well as subject matter of one or more of any combination of examples 29-51), wherein said treatment is disposed on an exterior portion of said substrate or component.

Example 53

The substrate or component of example 28 (as well as subject matter of one or more of any combination of examples 29-52), wherein said treatment is disposed on an interior portion of said substrate or component.

Example 54

The substrate or component of example 28 (as well as subject matter of one or more of any combination of examples 29-53), wherein said treatment is disposed on an exterior portion and an interior portion of said substrate or component.

Example 55

The substrate or component of examples 28-53, wherein said substrate or component (and related elements) may include any combination of one or more of the following:

a) an architectural structure (for example: pillars, walls, shielding, foundations or floors for tall buildings or pillars, wall shielding floors, for regular buildings and houses),

b) a civil engineering field structure (for example: road facilities such as noise resistant walls and crash barriers, road paving materials, permanent and portable aircraft landing runways, pipes, segment materials for tunnels, segment materials for underwater tunnels, tube structural materials, main beams of bridges, bridge floors, girders, cross beams of bridges, girder walls, piers, bridge substructures, towers, dikes and dams, guide ways, railroads, ocean structures such as breakwaters and wharf protection for harbor facilities, floating piers/oil excavation or production platforms, airport structures such as runways), military security/protection/defense structures,

c) a machine structure (for example: frame structures for carrying system, carrying pallets, frame structure for robots, etc.),

d) an automobile structure (for example: body, frame, doors, chassis, roof and floor, side beams, bumpers, etc.),

e) a ship structure (for example: main frame of the ship, body, deck, partition wall, wall, etc.),

f) a freight car structure (for example: body, frame, floor, wall, etc.),

g) an aircraft structure (for example: wing, main frame, body, floor, etc.),

h) a spacecraft structure (for example: body, frame, floor, wall, etc.),

i) a space station structure (for example: the main body, floor, wall, etc.),

j) a submarine, ship or water craft structure (for example: body, frame, etc.), and

k) a blast, ballistic, projectile, shock or impact resistant structure (or any combination thereof).

Example 56

The method of using any of the substrates or components (and related elements) provided in any one or more of examples 28-53.

Example 57

The method of manufacturing any of the substrates or components (and related elements) provided in any one or more of examples 28-53.

REFERENCES

The following patents, applications and publications as listed below and throughout this document are hereby incorporated by reference in their entirety herein. It should be appreciated that various aspects of embodiments of the present method, system, devices, structures, article of manufacture, and compositions may be implemented with the following methods, systems (e.g., systems for using, depositing, and manufacturing), devices, article of manufacture, and compositions disclosed in the following U.S. Patent Applications, U.S. Patents, and PCT International Patent Applications and are hereby incorporated by reference herein and co-owned (vast majority) with the assignee (and which are not admitted to be prior art with respect to the present invention by inclusion in this section):

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In summary, while the present invention has been described with respect to specific embodiments, many modifications, variations, alterations, substitutions, and equivalents will be apparent to those skilled in the art. The present invention is not to be limited in scope by the specific embodiment described herein. Indeed, various modifications of the present invention, in addition to those described herein, will be apparent to those of skill in the art from the foregoing description and accompanying drawings. Accordingly, the invention is to be considered as limited only by the spirit and scope of the following claims, including all modifications and equivalents.

Still other embodiments will become readily apparent to those skilled in this art from reading the above-recited detailed description and drawings of certain exemplary embodiments. It should be understood that numerous variations, modifications, and additional embodiments are possible, and accordingly, all such variations, modifications, and embodiments are to be regarded as being within the spirit and scope of this application. For example, regardless of the content of any portion (e.g., title, field, background, summary, abstract, drawing figure, etc.) of this application, unless clearly specified to the contrary, there is no requirement for the inclusion in any claim herein or of any application claiming priority hereto of any particular described or illustrated activity or element, any particular sequence of such activities, or any particular interrelationship of such elements. Moreover, any activity can be repeated, any activity can be performed by multiple entities, and/or any element can be duplicated. Further, any activity or element can be excluded, the sequence of activities can vary, and/or the interrelationship of elements can vary. Unless clearly specified to the contrary, there is no requirement for any particular described or illustrated activity or element, any particular sequence or such activities, any particular size, speed, material, dimension or frequency, or any particularly interrelationship of such elements. Accordingly, the descriptions and drawings are to be regarded as illustrative in nature, and not as restrictive. Moreover, when any number or range is described herein, unless clearly stated otherwise, that number or range is approximate. When any range is described herein, unless clearly stated otherwise, that range includes all values therein and all sub ranges therein. Any information in any material (e.g., a United States/foreign patent, United States/foreign patent application, book, article, etc.) that has been incorporated by reference herein, is only incorporated by reference to the extent that no conflict exists between such information and the other statements and drawings set forth herein. In the event of such conflict, including a conflict that would render invalid any claim herein or seeking priority hereto, then any such conflicting information in such incorporated by reference material is specifically not incorporated by reference herein. 

We claim:
 1. A method for strengthening a substrate or component with a treatment, said method comprising: treating the substrate or component to be strengthened; and wherein said treatment affects a minimum of at least about 0.5 percent of the material cross-sectional area of said substrate or said component after said treatment, resulting in strengthening of said substrate or said component.
 2. The method of claim 1, wherein said treatment affects at least about the following percentage of the material cross-sectional area: 0.5, 1.0, 1.5, 2.0, 2.5, 3.0, 3.5, 4.0, 4.5, 5.0, 5.5, 6.0, 6.5, 7.0, 7.5, 8.0, 8.5, 9.0, 9.5, 10.0, 10.5, 11.0, 11.5, 12.0, 12.5, 13.0, 13.5, 14.0, 14.5, 15.0, 15.5, 16.0, 16.5, 17.0, 17.5, 18.0, 18.5, 19.0, 19.5, 20.0, 20.5, 21.0, 21.5, 22.0, 22.5, 23.0, 23.5, 24.0, 24.5, 25.0, 25.5, 26.0, 26.5, 27.0, 27.5, 28.0, 28.5, 29.0, 29.5, 30.0, 30.5, 31.0, 31.5, 32.0, 32.5, 33.0, 33.5, 34.0, 34.5, 35.0, 35.5, 36.0, 36.5, 37.0, 37.5, 38.0, 38.5, 39.0, 39.5, 40.0, 40.5, 41.0, 41.5, 42.0, 42.5, 43.0, 43.5, 44.0, 44.5, 45.0, 45.5, 46.0, 46.5, 47.0, 47.5, 48.0, 48.5, 49.0, 49.5, 50.0, 50.5, 51.0, 51.5, 52.0, 52.5, 53.0, 53.5, 54.0, 54.5, 55.0, 55.5, 56.0, 56.5, 57.0, 57.5, 58.0, 58.5, 59.0, 59.5, 60.0, 60.5, 61.0, 61.5, 62.0, 62.5, 63.0, 63.5, 64.0, 64.5, 65.0, 65.5, 66.0, 66.5, 67.0, 67.5, 68.0, 68.5, 69.0, 69.5, 70.0, 70.5, 71.0, 71.5, 72.0, 72.5, 73.0, 73.5, 74.0, 74.5, 75.0, 75.5, 76.0, 76.5, 77.0, 77.5, 78.0, 78.5 79.0, 79.5, 80.0, 80.5, 81.0, 81.5, 82.0, 82.5, 83.0, 83.5, 84.0, 84.5, 85.0, 85.5, 86.0, 86.5, 87.0, 87.5, 88.0, 88.5, 89.0, 89.5, 90.0, 90.5, 91.0, 91.5, 92.0, 92.5, 93.0, 93.5, 94.0, 94.5, 95.0, 95.5, 96.0, 96.5, 97.0, 97.5, 98.0, 98.5, 99.0, 99.5, or 100.0; 0.5, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, 90, 91, 92, 93, 94, 95, 96, 97, 98, 99, or 100; 0.5-1, 2-3, 4-5, 6-7, 8-9, 10-11, 12-13, 14-15, 16-17, 18-19, 20-21, 22-23, 24-25, 26-27, 28-29, 30-31, 32-33, 34-35, 36-37, 38-39, 40-41, 42-43, 44-45, 46-47, 48-49, 50-51, 52-53, 54-55, 56-57, 58-59, 60-61, 62-63, 64-65, 66-67, 68-69, 70-71, 72-73, 74-75, 76-77, 78-79, 80-81, 82-83, 84-85, 86-87, 88-89, 90-91, 92-93, 94-95, 96-97, or 98-100; 0.5-5, 6-10, 11-15, 16-20, 21-25, 26-30, 31-35, 36-40, 41-45, 46-50, 51-55, 56-60, 61-65, 66-70, 71-75, 76-80, 81-85, 86-90, or 96-100; 0.5-10, 11-20; 21-30, 31-40, 41-50, 51-60, 61-70, 71-80, 81-90, 91-100; 10-35; 36-60; 61-80; or 81-100; 0.5-20; 21-40; 41-60; 61-80; or 81-100; 10-100; 5-100; 0.5-100; 25-100; 25-75; 10-25; 5-25; 0.5-25; 50-100; 75-100; 10-50; 5-50; 0.5-50 40-60; 30-70; 20-80; 25-75; or 50-75.
 3. The method of claim 1, wherein said strengthening comprises an increase in compression strength.
 4. The method of claim 1, wherein said strengthening comprises an increase in tensile strength.
 5. The method of claim 1, wherein said strengthening comprises an increase in shear strength.
 6. The method of claim 1, wherein said strengthening comprises an increase in fatigue strength.
 7. The method of claim 1, wherein said strengthening comprises an increase in fracture toughness.
 8. The method of claim 1, wherein said treating comprises nitriding.
 9. The method of claim 1, wherein said treating comprises carburizing.
 10. The method of claim 1, wherein said treating comprises carbonitriding.
 11. The method of claim 1, wherein said substrate or component comprises steel.
 12. The method of claim 1, wherein said substrate or component comprises iron.
 13. The method of claim 1, wherein said substrate or component comprises low-carbon steel.
 14. The method of claim 1, wherein said substrate or component comprises an iron based alloy.
 15. The method of claim 1, wherein said substrate or component comprises stainless steel.
 16. The method of claim 1, wherein said substrate or component comprises austenitic steel.
 17. The method of claim 1, wherein said substrate or component comprises martensitic steel.
 18. The method of claim 1, wherein said substrate or component comprises austenitic stainless steel.
 19. The method of claim 1, wherein said substrate or component comprises martensitic stainless steel.
 20. The method of claim 1, wherein said substrate or component is a micro truss.
 21. The method of claim 1, wherein said substrate or component is a hollow component.
 22. The method of claim 1, wherein said substrate or component is a solid component.
 23. The method of claim 1, wherein said substrate or component is a sub-millimeter sized component.
 24. The method of claim 1, wherein said substrate or component is a cellular material.
 25. The method of claim 1, wherein said treatment is disposed on an exterior portion of said substrate or component.
 26. The method of claim 1, wherein said treatment is disposed on an interior portion of said substrate or component.
 27. The method of claim 1, wherein said treatment is disposed on an exterior portion and an interior portion of said substrate or component.
 28. A strengthened substrate or component, wherein substrate or component comprising: said substrate or component in communication with a treatment; and said treatment comprising a minimum of at least about 0.5 percent of the total material cross-sectional area of said substrate or component in communication with said treatment.
 29. The substrate or component of claim 28, wherein said treatment affects at least about the following percentage of the material cross-sectional area: 0.5, 1.0, 1.5, 2.0, 2.5, 3.0, 3.5, 4.0, 4.5, 5.0, 5.5, 6.0, 6.5, 7.0, 7.5, 8.0, 8.5, 9.0, 9.5, 10.0, 10.5, 11.0, 11.5, 12.0, 12.5, 13.0, 13.5, 14.0, 14.5, 15.0, 15.5, 16.0, 16.5, 17.0, 17.5, 18.0, 18.5, 19.0, 19.5, 20.0, 20.5, 21.0, 21.5, 22.0, 22.5, 23.0, 23.5, 24.0, 24.5, 25.0, 25.5, 26.0, 26.5, 27.0, 27.5, 28.0, 28.5, 29.0, 29.5, 30.0, 30.5, 31.0, 31.5, 32.0, 32.5, 33.0, 33.5, 34.0, 34.5, 35.0, 35.5, 36.0, 36.5, 37.0, 37.5, 38.0, 38.5, 39.0, 39.5, 40.0, 40.5, 41.0, 41.5, 42.0, 42.5, 43.0, 43.5, 44.0, 44.5, 45.0, 45.5, 46.0, 46.5, 47.0, 47.5, 48.0, 48.5, 49.0, 49.5, 50.0, 50.5, 51.0, 51.5, 52.0, 52.5, 53.0, 53.5, 54.0, 54.5, 55.0, 55.5, 56.0, 56.5, 57.0, 57.5, 58.0, 58.5, 59.0, 59.5, 60.0, 60.5, 61.0, 61.5, 62.0, 62.5, 63.0, 63.5, 64.0, 64.5, 65.0, 65.5, 66.0, 66.5, 67.0, 67.5, 68.0, 68.5, 69.0, 69.5, 70.0, 70.5, 71.0, 71.5, 72.0, 72.5, 73.0, 73.5, 74.0, 74.5, 75.0, 75.5, 76.0, 76.5, 77.0, 77.5, 78.0, 78.5 79.0, 79.5, 80.0, 80.5, 81.0, 81.5, 82.0, 82.5, 83.0, 83.5, 84.0, 84.5, 85.0, 85.5, 86.0, 86.5, 87.0, 87.5, 88.0, 88.5, 89.0, 89.5, 90.0, 90.5, 91.0, 91.5, 92.0, 92.5, 93.0, 93.5, 94.0, 94.5, 95.0, 95.5, 96.0, 96.5, 97.0, 97.5, 98.0, 98.5, 99.0, 99.5, or 100.0; 0.5, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, 90, 91, 92, 93, 94, 95, 96, 97, 98, 99, or 100; 0.5-1, 2-3, 4-5, 6-7, 8-9, 10-11, 12-13, 14-15, 16-17, 18-19, 20-21, 22-23, 24-25, 26-27, 28-29, 30-31, 32-33, 34-35, 36-37, 38-39, 40-41, 42-43, 44-45, 46-47, 48-49, 50-51, 52-53, 54-55, 56-57, 58-59, 60-61, 62-63, 64-65, 66-67, 68-69, 70-71, 72-73, 74-75, 76-77, 78-79, 80-81, 82-83, 84-85, 86-87, 88-89, 90-91, 92-93, 94-95, 96-97, or 98-100; 0.5-5, 6-10, 11-15, 16-20, 21-25, 26-30, 31-35, 36-40, 41-45, 46-50, 51-55, 56-60, 61-65, 66-70, 71-75, 76-80, 81-85, 86-90, or 96-100; 0.5-10, 11-20; 21-30, 31-40, 41-50, 51-60, 61-70, 71-80, 81-90, 91-100; 10-35; 36-60; 61-80; or 81-100; 0.5-20; 21-40; 41-60; 61-80; or 81-100; 10-100; 5-100; 0.5-100; 25-100; 25-75; 10-25; 5-25; 0.5-25; 50-100; 75-100; 10-50; 5-50; 0.5-50 40-60; 30-70; 20-80; 25-75; or 50-75.
 30. The substrate or component of claim 28, wherein said strengthening comprises an increase in compression strength.
 31. The substrate or component of claim 28, wherein said strengthening comprises an increase in tensile strength.
 32. The substrate or component of claim 28, wherein said strengthening comprises an increase in shear strength.
 33. The substrate or component of claim 28, wherein said strengthening comprises an increase in fatigue strength.
 34. The substrate or component of claim 28, wherein said strengthening comprises an increase in fracture toughness.
 35. The substrate or component of claim 28, wherein said treated percentage has been nitrided.
 36. The substrate or component of claim 28, wherein said treated percentage has been carburized.
 37. The substrate or component of claim 28, wherein said treated percentage has been carbonitrided.
 38. The substrate or component of claim 28, wherein said substrate or component comprises steel.
 39. The substrate or component of claim 28, wherein said substrate or component comprises iron.
 40. The substrate or component of claim 28, wherein said substrate or component comprises low-carbon steel.
 41. The substrate or component of claim 28, wherein said substrate or component comprises an iron based alloy.
 42. The substrate or component of claim 28, wherein said substrate or component comprises stainless steel.
 43. The substrate or component of claim 28, wherein said substrate or component comprises austenitic steel.
 44. The substrate or component of claim 28, wherein said substrate or component comprises martensitic steel.
 45. The substrate or component of claim 28, wherein said substrate or component comprises austenitic stainless steel.
 46. The substrate or component of claim 28, wherein said substrate or component comprises martensitic stainless steel.
 47. The substrate or component of claim 28, wherein said substrate or component is a micro truss.
 48. The substrate or component of claim 28, wherein said substrate or component is a hollow component.
 49. The substrate or component of claim 28, wherein said substrate or component is a solid component.
 50. The substrate or component of claim 28, wherein said substrate or component is a sub-millimeter sized component.
 51. The substrate or component of claim 28, wherein said substrate or component is a cellular material.
 52. The substrate or component of claim 28, wherein said treatment is disposed on an exterior portion of said substrate or component.
 53. The substrate or component of claim 28, wherein said treatment is disposed on an interior portion of said substrate or component.
 54. The substrate or component of claim 28, wherein said treatment is disposed on an exterior portion and an interior portion of said substrate or component. 